Controlling plasma arc processing systems and related systems and devices

ABSTRACT

In some aspects, autonomous motion devices configured to operably connect to a plasma torch of a plasma cutting system can include: a body to support a power supply of the plasma cutting system and move relative to a workpiece; a torch holder connected to the body and configured to position a plasma arc torch tip of the plasma torch relative to a region of the workpiece to be processed; a drive system to translate the body supporting the power supply and torch autonomously relative to a surface of the workpiece during a plasma processing operation; and a processor in communication with the drive system and configured to communicate with the power supply, the processor being configured to control the translation of the body relative to the workpiece in accordance with the plasma processing operation.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/589,447, filed May 8, 2017, which claims the benefit of U.S.Provisional Patent Application Ser. No. 62/332,624 filed May 6, 2016,entitled “Remote Control Plasma Cutting/Gouging System.” Theseapplications are owned by the assignee of the instant application andare hereby incorporated herein by reference in their entirety.

TECHNICAL FIELD

This disclosure relates generally to plasma arc processing systems, andmore specifically to controlling plasma arc processing systems and torelated systems and methods.

BACKGROUND

Plasma arc cutting torches are widely used in the cutting, gouging andmarking of materials. A plasma arc torch generally includes anelectrode, a nozzle having a central exit orifice mounted within a torchbody, electrical connections, passages for cooling, and passages for arccontrol fluids (e.g., plasma gas). Optionally, a swirl ring is employedto control fluid flow patterns in the plasma chamber formed between theelectrode and the nozzle. In some torches, a retaining cap can be usedto maintain the nozzle and/or swirl ring in the plasma arc torch. Inoperation, a plasma arc torch produces a plasma arc, which is aconstricted jet of mostly ionized gas with high temperature and that canhave sufficient momentum to assist with removal of molten metal. Aplasma cutting system can include at least one plasma arc torch, a powersource for supplying power to the plasma arc torch, and a gas source forsupplying a gas (e.g., air) to the plasma arc torch to support varioustorch operations.

Typically, plasma arc torches are coupled to large and/or heavy (e.g.,stationary) power supplies by lead lines that provide the electricityand pressurized gases needed to form a plasma jet. The lead linestypically are made to have a defined length which can limit the abilityto perform a plasma processing operation beyond a certain length fromthe stationary power supply.

SUMMARY

In some aspects, autonomous motion devices configured to operablyconnect to a plasma torch of a plasma arc processing system can include:a body to support a power supply of the plasma cutting system and moverelative to a workpiece; a torch holder connected to the body andconfigured to position a plasma arc torch tip of the plasma torchrelative to a region of the workpiece to be processed; a drive system totranslate the body supporting the power supply and torch autonomouslyrelative to a surface of the workpiece during a plasma processingoperation; and a processor in communication with the drive system andconfigured to communicate with the power supply, the processor beingconfigured to control the translation of the body relative to theworkpiece in accordance with the plasma processing operation.

Embodiments can include one or more of the following features.

The motion devices can include a set of sensors configured to monitor atleast one characteristic of the plasma processing operation or thetranslation of the body relative to the workpiece. The set of sensorscan include a light sensor configured to monitor cut quality. Aprocessor can be configured to communicate feedback from the set ofsensors to the plasma cutting system. The set of sensors can obtaininformation to determine a travel path of the autonomous motion device.The motion devices can include one or more Internet-of-things (IOT)devices configured to collect operational data for transmission tomobile devices.

The torch holder can be configured to manipulate the plasma arc torchtip along at least one of an x, y, or z axes relative to the body. Themanipulation of the plasma arc torch tip can include at least one ofpositioning or actuating the torch tip.

The processor can be configured to be separated and reconnected to thepower supply for operation of the plasma arc processing system and theautonomous motion device.

The motion devices can include a gas supply configured to travel withthe body.

The motion devices can include a control device in communication withthe processor. The drive system can include an omnidirectional roboticdrive system.

The motion devices can include a means to monitor a travel path of themotion device during the plasma processing operation. The means tomonitor a travel path of the motion device can include a means toprovide travel path information to the processor to carry out a feedbackloop to control the translation of the body relative to the workpiece inaccordance with the plasma processing operation. The means can include aprobe to physically detect a planned plasma processing path.

In some aspects, autonomous plasma arc processing systems can include: aplasma torch power supply configured to generate a plasma arc; a plasmaarc torch operably connected to the power supply; an autonomouspressurized gas source fluidly connected to the plasma arc torch; and anautonomous motion device operably connected to the plasma arc torch andsupporting the power supply, the motion device having: a body to supportthe power supply and move relative to a workpiece; a torch holderconnected to the body and configured to position a plasma arc torch tipof the plasma arc torch relative to a region of the workpiece to beprocessed; a drive system to translate the body supporting the powersupply and torch autonomously relative to a surface of the workpieceduring a plasma processing operation; and a processor in communicationwith the drive system and configured to communicate with the powersupply, the processor being configured to control the translation of thebody relative to the workpiece in accordance with the plasma processingoperation.

In some aspects, methods of operating a plasma arc processing systemwith an autonomous motion device configured to move the plasma arcprocessing system relative to a workpiece can include: initiating aplasma arc from a torch tip of a plasma torch of the plasma arcprocessing system operably connected to the motion device, the plasmaarc beginning a plasma processing operation on the workpiece;autonomously moving the motion device, the motion device supporting theplasma arc processing system, relative to the workpiece to perform theplasma processing operation along an intended processing path of theworkpiece; and extinguishing the plasma arc.

Embodiments can include one or more of the following features.

The methods can also include monitoring the plasma processing operationusing one or more sensors disposed on the autonomous motion device. Themethods can also include manipulating the torch tip relative to theworkpiece during the movement relative to the workpiece. The methods canalso include determining a planned travel path along the workpiece toperform the plasma processing operation.

Embodiments described herein can have one or more of the followingadvantages.

In some aspects, the systems and methods described herein can providefor system level integration of components and functions that areconventionally configured separately, which can provide an all-in-onesolution that delivers a simple, mobile, easy to manage solution for thecustomer.

Additionally, in some aspects, the autonomous systems and methodsdescribed herein can provide for improved performance for remoteautomated gouging and cutting. For example, the autonomous systems andmethods described herein can be used to access hard-to-reach areas orregions to be cut or gouged. Additionally or alternatively, the systemsand methods described herein can be used to perform longer continuouscuts or gouges than can be performed by conventional plasma arc systems.Specifically, most plasma processing operations are constrained by alength of the torch lead line such that a cut is stopped when the plasmatorch reaches the end of the lead line. Thus, the cut needs to bestopped, the power supply or workpiece needs to be moved relative to oneanother, all before a new cut can be performed. Whereas, with the powersupply being carried relative to a workpiece on the motion devicedescribed here, the cut is not constrained by a torch lead line lengthand a cut can be performed continuously along long lengths.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side schematic side view of an example autonomous motiondevice configured to support and carry a plasma arc processing systemand a plasma arc torch.

FIG. 2 is a perspective view of an example autonomous motion deviceconfigured to support and carry a plasma arc processing system.

FIG. 3 is a schematic view of an example autonomous motion devicecontrol network.

DETAILED DESCRIPTION

In some aspects, the systems and methods described herein can be used tocreate plasma arc processing systems that are more accessible andautonomous than some conventional systems by locating (e.g.,positioning, packaging) system components, such as the power supply andtorch on a motion device (e.g., an autonomous robotic system) configuredto carry the power supply and torch together relative to a workpieceduring a processing operation.

For example, in some embodiments, referring to FIGS. 1-3, a motiondevice (e.g., an autonomous motion device) 100 is configured to operablyconnect to a plasma torch 50 operably connected to a plasma arcprocessing system 75. The motion device 100 can include a body 110 tosupport a power supply 80 of the plasma cutting system 75 configured togenerate a plasma arc. The body 110 is typically configured to movealong or otherwise relative to a workpiece 25.

The motion device 100 can include a torch holder 120 connected to thebody 110 and configured to position a plasma arc torch tip 55 of theplasma torch 50 relative to a region of the workpiece 25 to beprocessed. As depicted, in some embodiments, the torch holder 120 isindirectly coupled to the body 110 and can be configured to moverelative to the body 110. Additionally, in some embodiments, the torchholder 120 can be affixed on or otherwise be a component of the body110.

In some embodiments, the torch holder 120 is configured to articulatethe torch 50 and torch tip 55 in order to carry out one or more ofvarious plasma processing operations. For example, the torch holder 120can be configured to manipulate the plasma arc torch tip 55 along, orrotate relative to, at least one of an x, y, or z axes relative to thebody 110. In some cases, the manipulation of the plasma arc torch tip 55includes at least one of positioning or actuating the torch tip 55relative to a workpiece 25 to be processed. While the examples depictedin FIG. 1 illustrate the torch holder 120 being separate from the powersupply 80, other examples are possible. For example, briefly referringspecifically to FIG. 2, in some embodiments, the torch holder 120 iscoupled to the body 110 and moves directly with the power supply 80.

Referring generally back to FIGS. 1-3, the motion device 100 can alsoinclude a drive system 130 to translate the body 110 supporting thepower supply 80 and torch 50 autonomously relative to a surface of theworkpiece 25 during a plasma processing operation. In some embodiments,such as those in which the torch holder 120 is indirectly connected tothe body 110, the drive system 130 can also be configured to move thetorch holder 120 relative to the workpiece 25. For example, the torchholder 120 can be configured to articulate a plasma torch (or multipletorches) in the X, Y, and Z directions.

The drive system 130 can include any of various robotic systemsconfigured to translate (e.g., convey, move, propel, drive) the body andthe plasma processing system, such as robotic systems having one or morepowered wheels and/or tracks that can be operated to translate themotion device. In some cases, the drive system 130 can include multiplewheels or tracks that can be operated in unison or independently fromone another. The drive system can include means, or otherwise beconfigured, for locomotion in a constant or indexed fashion in anydirection or position (e.g., horizontal or vertical motion with respectto a ground plane). For example, the drive system 130 can include anomnidirectional robotic drive system. In some cases, the drive system130 can be configured to control oscillation, torch height control,pendulum motion, etc.

In some embodiments, the drive system 130 can include integrateddirectional guidance or one or more guiding tracks to attach to theworkpiece, such as using magnetic forces, vacuum, adhesives, mechanicalfasteners, etc. The drive system 130 can include means, or otherwise beconfigured, to accelerate/decelerate, and to travel at speeds consistentin accordance with a desired plasma processing process to be performed.

A processor 112 can be disposed in and/or on the motion device 100 andbe in communication with the drive system 130. The processor 112 canalso be configured to communicate with the power supply 80 so that themotion device 100 and plasma arc processing system 75 can be controlledin combination with one another. For example, the processor 112 can beconfigured to control the translation of the body 110 relative to theworkpiece 25 in accordance with the plasma processing operation. In someembodiments, the processor 112 can also be configured to communicatewith the torch holder 120. In some embodiments, the processor 112 can beconfigured to control and operate body 110, torch holder 120, and plasmaarc processing system 75 collaboratively (e.g., simultaneously, inunison, etc.) to perform a plasma processing operation. In someembodiments, the processor 112 is configured to be separated andreconnected to the power supply 80 for operation of the plasma arcprocessing system 75 and the autonomous motion device 100.

In some embodiments, the motion device 100 includes a means to monitor atravel path of the motion device 100 during the plasma processingoperation. For example, in some cases, the motion device 100 can alsoinclude a set of sensors configured to monitor at least onecharacteristic of the plasma processing operation and/or the translationof the body 110 relative to the workpiece 25. Sensors can includeproximity sensors (e.g., using light, capacitance, inductance),triangulation sensors, light reflection sensors using light from plasmaprocess or material emissivity, voltage potential sensors, soundsensors, vibration sensors, temperature sensors, and sensors observingspeed, acceleration, tilt/position of the torch. For example, thesensors can include a light or thermal sensor configured to monitor cutquality of a plasma processing operation being performed. The light orthermal sensor observing the plasma process can provide data (e.g., datarelating to light intensity, flash frequency, arc brightness, etc.) tothe system 75 to analyze system performance. In some cases, a processor(e.g., the processor 112) is configured to communicate feedback from thesensors to the plasma cutting system 75. For example, a feedback loopcan be created in which the sensors can provide information on a cutbeing performed and the system 75 and motion device 100 can adjust(e.g., alter, modify, update, or otherwise change) an operation in orderto modify the cut being performed. Thus, the means to monitor a travelpath of the motion device can include a means to provide travel pathinformation to the processor to carry out a feedback loop to control thetranslation of the body relative to the workpiece in accordance with theplasma processing operation. The means to provide travel pathinformation can include start/stop instructions, torch positioninginstructions, or other process parameters, such as plasma current, torchgas flow, or ramp up or ramp down.

That is, in some examples, plasma arc processing system 75 and motiondevice 100 can be programmed to perform a cut or gouge along apredetermined or planned path with certain parameters (e.g., cut speed,current, gas pressure) and, based on feedback from the sensors, theprogrammed cut parameters can be updated as the cut is being performed.

In some cases, the sensors can be used to obtain information (e.g.,data) to determine a desired travel path for the motion device for aprocessing operation. For example, the sensors can include an opticalsensor that visually inspects a workpiece to be processed and determineswhere the motion device 100 should travel to perform an operation. Insome embodiments, the sensors can include a physical sensor (e.g., aprobe) to tactilely determine or predict a cutting path and thereforealso a travel path of the motion device. For example, a probe can beused to feel a region of a workpiece to determine where the workpiece isto be cut or gouged and upon receiving information from the sensors, theprocessor 112 can re-program the motion device 100 and/or the plasma arcprocessing system 75 accordingly. Thus, in some cases, the means tomonitor a travel path can include a probe to physically detect a plannedplasma processing path.

In some embodiments, the motion device 100 can include one or moredevices configured to collect operational data for transmission tomobile devices. For example, the motion device 100 can include one ormore Internet-of-things (IOT) devices. In some cases, IOT devices caninclude wired or wireless devices capable of collecting, storing, ortransmitting data, such as cell phones, tablets, PCs, or other devicescontaining hardware, firmware, or software. Other examples can includecontrols features and user interface devices.

In some embodiments, the autonomous motion device 100 includes a gassupply, which can be configured to travel with the body. In some cases,the gas supply can include an autonomous pressurized gas source fluidlyconnected to the power supply 80 and the plasma arc torch 50. Forexample, in some cases, the gas supply can include a gas tank orcompressor disposed on the body 110. Including the gas supply on themotion device 100 (e.g., on the body 110), in a portable form, can helpmake the motion more portable and adaptable for various processingoperations without being tethered, for example, to a shop gas supply.

Briefly referring to FIG. 3, the autonomous motion device 100 caninclude a control device (e.g., controller) 150 in communication withthe processor 112. The control device 150 can be used to direct orremote control the operation of the plasma arc processing system 75and/or the motion device 100. In some embodiments, the control device150 can be in the form of a dedicated handheld controller. Alternativelyor additionally, the control device 150 can be in the form of a cellulartelephone, tablet, or other computing device. The control device 150 canbe in wired or wireless communication with the power supply 80 and/orthe motion device 100. Thus, in some cases, various components (e.g.,the power supply 80, motion device 100, body 110, torch holder 120, andcontrol device 150) can include wireless transmitters/receivers 125 tosend and receive information. In some embodiments, the control device150 can receive information (e.g., information relating to a processingoperation being performed) from the motion device 100 and provideinformation to the power supply 80 and the motion device 100. Thus, afeedback communication and control loop can be formed. As discussedabove, while the examples depicted in FIG. 3 illustrate the power supply80 being disposed separately from the torch holder 120, the torch holder120 and motion device 100 can be disposed together as a common roboticcomponent on the body 110.

The communication system between the motion device 100, control device150 and plasma processing system 75 can be configured to control varioussystem functions. For example, the control device 150 can be used forsystem level process controls and status indicators, power up and/ordown, safety functions, and IOT connectivity or system interfacing.

The systems described herein can be used to carry out any of variousplasma arc processing operations. For example, in some embodiments,methods of operating a plasma arc processing system with an autonomousmotion device configured to move the plasma arc processing systemrelative to a workpiece can first include initiating a plasma arc from atorch tip of a plasma torch of the plasma arc processing system operablyconnected to the motion device, the plasma arc beginning a plasmaprocessing operation on the workpiece. For example, the plasma arcprocessing system 75 can initiate a plasma arc in a torch tip 55 tobegin a plasma processing operation on the workpiece 25.

The methods can include autonomously moving the motion device, where themotion device supports the plasma arc processing system, relative to theworkpiece to perform the plasma processing operation along an intendedprocessing path of the workpiece. For example, the drive system 130 canmove the body 110 and the plasma arc processing system disposed thereonrelative to the workpiece 25.

In some embodiments, the methods can include monitoring the plasmaprocessing operation being performed using one or more sensors disposedin or on the autonomous motion device. As discussed above, visual orthermal sensors can be used to monitor the plasma processing operationand the system can determine if any of various modifications of changesin system parameters are desired. For example, the sensors can track andmonitor ongoing cut quality and adapt the cutting process accordingly.In some cases, the methods can include manipulating the torch tiprelative to the workpiece during the movement relative to the workpiece.

Additionally or alternatively, in some embodiments, the methods caninclude determining a planned travel path along the workpiece to performthe plasma processing operation. For example, the sensors can alsoinclude physical sensors, such as the probes discussed above, that canfeel the regions to be processed as the plasma arc processing system andmotion device moves along the workpiece. In some cases, a probe can feela joint to be subsequently welded, in which positioning spot welds areto be removed by gouging prior to welding, and the travel path of themotion device can be updated to following the joint. Once the desiredplasma arc processing operation is performed, the methods can includeextinguishing the plasma arc.

While various embodiments have been described herein, it should beunderstood that they have been presented and described by way of exampleonly, and do not limit the claims presented herewith to any particularconfigurations or structural components. Thus, the breadth and scope ofa preferred embodiment should not be limited by any of theabove-described exemplary structures or embodiments, but should bedefined only in accordance with the following claims and theirequivalents.

What is claimed:
 1. An autonomous motion device configured to operablyconnect to a plasma arc torch of a plasma arc processing system, theautonomous motion device comprising: a body connected to a torch holderand movable relative to a workpiece, the torch holder configured toposition a plasma arc torch tip of the plasma arc torch relative to aregion of the workpiece to be processed; a drive system to translate thebody, which translates the torch holder, autonomously relative to asurface of the workpiece during a plasma processing operation; a set ofone or more sensors configured to monitor at least one characteristic ofthe plasma processing operation or the translation of the body relativeto the workpiece; and a processor in communication the set of sensors,the processor being configured to receive feedback from the set ofsensors to control the translation of the body relative to the workpieceand to communicate with the plasma arc processing system to update oneor more cutting parameters during the plasma processing operation, theone or more cutting parameters not including torch positioninginstructions.
 2. The autonomous motion device of claim 1 wherein the setof sensors include a light sensor configured to monitor cut quality. 3.The autonomous motion device of claim 1 wherein the set of sensorsobtain information to determine a travel path of the autonomous motiondevice.
 4. The autonomous motion device of claim 1 further comprisingone or more Internet-of-things (IOT) devices configured to collectoperational data for transmission to mobile devices.
 5. The autonomousmotion device of claim 1 wherein the torch holder is configured tomanipulate the plasma arc torch tip along at least one of an x, y, or zaxes relative to the body.
 6. The autonomous motion device of claim 5wherein the manipulation of the plasma arc torch tip includespositioning the torch tip.
 7. The autonomous motion device of claim 1further comprising a gas supply configured to travel with the body. 8.The autonomous motion device of claim 1 further comprising a controldevice in communication with the processor.
 9. The autonomous motiondevice of claim 1 wherein the motion device comprises a means to monitora travel path of the motion device during the plasma processingoperation, the means comprising the set of one or more sensorsconfigured to monitor at least one characteristic of the plasmaprocessing operation or the translation of the body relative to theworkpiece.
 10. The autonomous motion device of claim 9 wherein the meansto monitor a travel path of the motion device further comprises a meansto provide travel path information to the processor to carry out afeedback loop to control the translation of the body relative to theworkpiece in accordance with the plasma processing operation.
 11. Theautonomous motion device of claim 1 wherein the drive system comprisesan omnidirectional robotic drive system.
 12. The autonomous motiondevice of claim 9 wherein the set of one or more sensors comprises aprobe to physically detect a planned plasma processing path.
 13. Theautonomous motion device of claim 1, further comprising a power supplysupported by the body to move relative to the workpiece.
 14. Theautonomous motion device of claim 13, wherein the torch holder isindirectly connected to the body via the power supply.
 15. Theautonomous motion device of claim 1, wherein the torch holder is affixedto the body.
 16. The autonomous motion device of claim 1, wherein thecutting parameters include at least one of cut speed, plasma current orgas pressure.
 17. A method of operating a plasma arc processing systemwith an autonomous motion device, the method comprising: initiating aplasma arc from a torch tip of a plasma arc torch of the plasma arcprocessing system, the plasma arc torch operably connected to the motiondevice, the plasma arc beginning a plasma processing operation on theworkpiece; autonomously moving the motion device, the motion devicesupporting the plasma arc torch, relative to the workpiece to performthe plasma processing operation along an intended processing path of theworkpiece; monitoring the plasma processing operation using one or moresensors disposed on the motion device; updating one or more cuttingparameters during the plasma processing operation based on feedback fromthe one or more sensors, the one or more cutting parameters notincluding torch positioning instructions; and extinguishing the plasmaarc.
 18. The method of claim 17 further comprising manipulating thetorch tip relative to the workpiece during the movement relative to theworkpiece.
 19. The method of claim 17 further comprising determining aplanned travel path along the workpiece to perform the plasma processingoperation.
 20. The method of claim 17, wherein the cutting parametersinclude at least one of cut speed, plasma current or gas pressure. 21.An autonomous plasma arc processing system comprising: a plasma torchpower supply configured to generate a plasma arc; a plasma arc torchoperably connected to the power supply; an autonomous pressurized gassource fluidly connected to the plasma arc torch; and an autonomousmotion device operably connected to the plasma arc torch and supportingthe plasma arc torch, the motion device comprising: a body connect to atorch holder and movable relative to a workpiece, the torch holderconfigured to position a plasma arc torch tip of the plasma arc torchrelative to a region of the workpiece to be processed; a drive system totranslate the body, which translates the torch holder, autonomouslyrelative to a surface of the workpiece during a plasma processingoperation; a set of one or more sensors configured to monitor at leastone characteristic of the plasma processing operation or the translationof the body relative to the workpiece; and a processor in communicationwith the drive system and configured to communicate with the set ofsensors, the processor being configured to receive feedback from the setof sensors to control the translation of the body relative to theworkpiece and to update one or more cutting parameters during the plasmaprocessing operation, the one or more cutting parameters not includingtorch positioning instructions.
 22. The method of claim 21, wherein thecutting parameters include at least one of cut speed, plasma current orgas pressure.